Camper with expandable top

ABSTRACT

An expandable bellows assembly for campers, or the like, adapted to be connected to a roof portion having downwardly extending peripheral sides which surround and house expandable walls when they are in the collapsed position. The bellows assembly is comprised of inner and outer sheets of flexible fabric reinforced plastic with a plurality of spaced horizontal seams which form pockets between the sheets, each pocket containing a rigid fiber glass slat, the slats being arranged to provide straight corner edges when the bellows are fully extended. The slats forming the first pair of parallel side walls are rectangular in shape, while those forming the second pair of parallel walls are trapezoidal with adjacent edges of the adjacent slats being of equal length, such as to provide triangular sections of material which are free to flex as the bellows are collapsed and expanded.

I Umted stateS Patent 1 [111 3,744,841 Schmidt July 10, 1973 CAMPER WITH EXPANDABLE TOP Primary ExaminerPhilip Goodman [76] lnventor: Leo Schmidt, 8500 Second Street O and Harvey N.W., Albuquerque, N. Mex. 87101 Jacobson [22] Filed: May 11, 1971 [57] ABSTRACT PP N05 142,281 An expandable bellows assembly for campers, or the Rehted s Application Dam like, adapted to be connected to a roof portion having [63] Continuatiomim an of Ser No 863 981 Oct 6 downwardly extending peripheral sides which surround 1969 Pat NO 3p622 193 and house expandable walls when they are in the collapsed position. The bellows assembly is comprised of 52 us. Cl. 296/27 52/64 innerand wheels flexible fabric reinfmed Plas- 51 int. 366 3 34 tic a plurality spaced hrizmal seams [58] Field of Search R 2 2 form pockets between the Sheets each pocket contain- R 5 A 5 R, a fiber Slat, the slats being arranged to 206 provide straight comer edges when the bellows are fully extended. The slats forming the first pair of paral- [56] References Cited lel side walls are rectangular in shape, while those forming the second pair of parallel walls are trapezoidal UNITED STATES PATENTS with adjacent edges of the adjacent slats being of equal ThOl'llpSOl'l R length such as to provide triangular ections of mate- 1 rial which are free to flex as the bellows are collapsed 315341512 10/1910 Ballas 52/67 expanded 7 Claims, 8 Drawing Figures PATENTEB 3. 744.841

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IIIIJZIIl/lll/IllI/I[71/11/11] iiliim Lea Schmidt CAMPER WITH EXPANDABLE TOP This application is a continuation-in-part of U.S. application Ser. No. 863,981, filed Oct. 6, 1969, now U.S. Pat. No. 3,622,193.

The present invention is related to camper constructions, and more particularly to vehicle mountable camper constructions with expandable side walls.

In the past, expandable, collapsible camper constructions have been manufactured to provide more compact camper assemblies which could be easily transported between camp sites. Such constructions, while providing the benefits of compactness were often made of extremely light materials which tended to wear quickly and which did not adequately withstand the many weather conditions often encountered during camping. These conventional structures did not provide sufficient insulation and protection against the cold, and were often susceptible to damage or destruction by even moderate winds. While more durable constructions have been provided, such have been very costly to produce, and increased the over-all weight beyond acceptable levels.

It is an object of the present invention to provide an expandable camper construction which is relatively inexpensive to produce, and lightweight, yet durable, well insulated, and able to withstand the elements of the weather.

Another object of the present invention is to provide a versatile expandable bellows construction for a camper which forms relatively rigid side walls capable of withstanding high winds and which provides adequate insulation for colder, more severe camping conditions.

It is a further object of the present invention to provide an expandable bellows assembly for a transportable camper, the assembly being made of a pair of highly durable, fabric reinforced plastic sheets with elongated fiber glass slats therebetween, arranged in a manner to provide relatively rigid side walls when in the expanded position, yet which may be easily collapsed into an extremely compact position during travel from one location to another.

Still another object of the present invention is to provide an expandable camper construction having a rigid roof section with downwardly extending peripheral side portions which serve to surround and enclose the bellows assembly when in the collapsed position, thereby providing a protective shield for the assembly during transportation.

It is still another object of the present invention to provide a method of producing an expandable bellows assembly for a camper, by sewing a plurality of horizontal spaced seams between flexible inner and outer sheets of fabric reinforced plastic, to form pockets therebetween, and inserting relatively rigid elongated slats in the pockets to provide a rigid, insulated side wall construction which may be easily flexed between an expanded position and a collapsed position.

These together with other objects andv advantages which will become subsequently apparent reside in the details of construction and operation as more fully hereinafter described and claimed, reference being had to the accompanying drawings forming a part hereof, wherein like numerals refer to like parts throughout, and in which:

FIG. 1 is a perspective view of the camper construction of the present invention mounted on a pickup truck, and in the fully expanded position;

FIG. 2 is a perspective view of the bellows assembly in the fully collapsed position;

FIG. 3 is a sectional view of the bellows assembly of the present invention in the almost fully collapsed position;

FIG. 4 is a partial perspective view of a corner por-.

tion of the bellows assembly with portions removed to expose the rigid slats;

FIG. 5 is a sectional view of the front seam of the bellows assembly taken along section 5-5 of FIG. 1;

FIG. 6 is a layout view of the flexible material with horizontal seams therein prior to inserting the rigid slats;

FIG. 7 is a broken side view of a typical rectangular slat which is inserted into the pockets between the layers of flexible material; and

FIG. 8 is a broken side view of a typical trapezoidal slat which is inserted into the pockets formed between the layers of material.

Referring now more particularly to FIG. 1, the camper construction of the present invention is generally indicated by the numeral 10, and is mounted onto a typical pickup truck 12 and may be fastened thereto by means not shown. The top portion of the camper construction is comprised of a bellows assembly 14 which is connected between a rigid lower portion 16 of the camper construction and a rigid roof portion 18 to provide additional vertical height to the camper construction when in the fully expanded position, as illustrated in FIG. 1.

Looking now to FIGS. 2 and 3, it can be appreciated that bellows assembly 14 may be fully collapsed, such that roof portion 18 overlaps and partially encompasses lower rigid portion 16 to enclose the bellows during transportation from one location to another. Roof portion 18 is constructed of a plurality of peripheral support members 20 and a flat horizontal portion 24 of sheet metal, or the like. Preferably, insulated material 22 is sandwiched between the top layer of sheet metal 24 and a lower layer of rigid material 26, such as fiberboard. The outer peripheral edge of roof member 18 is surrounded by a downwardly extending peripheral side walls 28, which may also be covered with a layer of a sheet material 30, and may be fastened to peripheral support member 20 with a conventional metal corner strip 32 covering its upper edge. Preferably, a sealing gasket is provided between corner strip 32 and the abutting layer of sheet metal 24 to seal the members against the entrance of rainwater and other contaminants.

It can be seen that the bellows assembly is comprised of inner and outer sheets 36 and 38 of flexible, fabric reinforced plastic, which are joined by a plurality of spaced horizontal seams 40 formed by conventional sewing techniques, or by cementing or otherwise bonding the sheets together. The horizontal seams 40 are vertically spaced from each other, such as to provide a plurality of elongated pockets formed between the inner and outer sheets to accommodate relatively rigid slats 42 of fiber glass reinforced plastic, or the like. The dimension of each slat 42 is such that it is slightly less than the corresponding dimension of each pocket, such as to provide sufficient freedom to allow the bellows to flex within the area of each seam 40.

Preferably, the inner and outer sheets 36 and 38 are formed from a single piece of material which is folded along an edge which is mounted between support members to assure against the entrance of water and similar contaminants between the sheets. The lower peripheral portion 46 of the bellows assembly may be fastened to the lower rigid portion 16 of the camper construction by way of an elongated mounting strip 48 of aluminum or similar material, with wood screws 50 or similar fasteners extending therethrough.

In order to provide proper flexing of the bellows assembly, it is essential that the corner portions and rigid slats be properly shaped to permit such operation. The shape of an inside corner portion can be seen in detail by referring to FIG. 4. It is seen, that a plurality of rectangular slats 42 are inserted into the pockets formed in side wall 52, while slats 54 of generally trapezoidal shape, are inserted into the corresponding pockets of end wall 56. The adjacent edges 58 of each adjacent slat 54 are of equal length, such as to provide triangular areas 60 at the ends of each slat which are free to flex during movement of the bellows assembly. It should also be noted, that in each triangular flexing section 60 the inner sheet has been cut away, such that, essentially, only the outer sheet flexes in this area. However, in the area of the seam 40 the inner sheet is not removed adjacent to the flexing section, such that a thin seam portion 62 separates each triangular section 60, thus providing additional strength to the seam in the area which receives additional stress due to continuous flexing.

Referring to FIG. 6, the layout shape of the sheets, flexing sections and seams can be seen in more detail. It is appreciated that each triangular flexing section 60 assumes the shape of a right triangle, with the hypotenuse of each triangle joining that of the adjacent triangle to form a zigzag pattern extending in a vertical direction along a line 64 which defines a corner of the bellows assembly when mounted to the camper construction. Accordingly, there is one elongated seam portion 62 for each pair of triangular sections 60, each extending between adjacent legs of the triangles.

The shapes of the rigid slats are illustrated in FIGS. 7 and 8. Each rectangular-shaped slat 42 is provided with smoothly rounded corners 66 which prevent puncturing or tearing of the plastic sheets during collapse and expansion of the bellows assembly. Similarly, each of the trapezoidal slats 54 is provided with rounded corner portions 68 which extend into the area separating the rectangular slats 42 as the assembly is collapsed, as shown in FIG. 3. The over-all length of each trapezoidal slat 54 is such that there is adequate space between each seam 40 and each end corner 68 that flexing and collapse of the bellows assembly will not be hindered in any way.

Preferably, the rectangular slats 42 are inserted into the pockets in each side wall of the bellows assembly, while the trapezoidal shaped slats are used in each of the end walls. It can be seen from FIG. 1, that when the bellows assembly is in the fully extended position the end edges of the rectangular slats will align with each other to form a straight edge 71 at each corner. As

such, the slats provide relatively rigid side walls when the bellows assembly is extended, thus providing additional strength not only to the bellows assembly, but to the roof portion supported in part by the bellows assembly. Each corner 68 of the trapezoidal slats extends close to each of the side walls to provide additional support when the side walls may be flexed under the influence of wind, or similar conditions. Furthermore, it is appreciated that the slats, being of fiber glass reinforced plastic, provide a wall of insulation between the inner and outer sheets, and thus, except for the small seam areas separating each slat, the entire area of each side wall is provided with an insulation barrier. A similar insulation barrier is provided for the end walls, with the exception of the triangular flexing areas into which the slats do not extend.

While it is appreciated that the construction of the bellows assembly of the present invention provides a relatively rigid structure with an insulation barrier therein, it should also be noted that the method of manufacture is relatively simple and inexpensive, thereby further enhancing the advantages of the invention. Preferably, the basic steps of manufacture are as follows. A single sheet of fabric reinforced plastic of suitable quality and strength is cut and dimensioned to have an over-all length slightly greater than the perimeter of the desired bellows assembly, and having a width approximately twice the dimension of the height of the bellows assembly when fully extended. The fabric is folded along its length, thereby halving the width and providing a double layer of fabric, corresponding to the inner and outer sheets, and forming an upper fold or edge which ultimately corresponds to edge 44, as shown in FIGS. 3 and 6. The overlapping sheets of fabric are then fastened together by a plurality of seams, or the like, each of which extends the entire length of the folded sheets, as shown in FIG. 6, thus forming a plurality of elongated pockets between the sheets. When forming the seams, an upper area 70 of material extending downwardly from the fold is provided such corresponding to the height of the abutting surfaces of support members 20. Likewise, a lower section of fabric, corresponding to 46, is provided immediately below the lowermost horizontal seam for fastening to the lower rigid portion of the camper. After the seams have been completed, the position of each corner is determined and sections of the inner fabric may be cut away to form the triangular flexing sections 60 of single sheet thickness. However, when double thickness is found to be satisfactory, such as with light materials, this step may be eliminated. The double layer of material, however, such as 62 should be left intact to provide additional strength in these areas. Subsequently, the end edges of folded fabric are sewn together to form a seam, such as that shown in FIG. 5, thus providing a continuous length of material corresponding to the perimeter of the ultimate bellows assembly. Each of the slats 42 and 54 are inserted into the appropriately formed pockets to provide rigidity and shape to the bellows assembly which is then fastened to the camper as shown in FIG. 3. Thus, it is seen that a versatile, relatively simple and inexpensive method of manufacturing an expandable bellows assembly is provided.

It should be noted, that minor changes in materials, the number of slats or the type of seams are deemed to fall within the scope of the present invention. It is also foreseeable that different fabrics could be used, so long as they are relatively flexible in nature to permit collapsing and expanding the bellows assembly. Also, the slats could be formed of materials such as wood, metal, fiberboard, or the like, so long as they provide the desired rigidity.

The foregoing is considered as illustrative only of the principles of the invention. Further, since numerous modifications and changes will readily occur to those skilled in the art, it is not desired to limit the invention to the exact construction and operation shown and described, and accordingly all suitable modifications and equivalents may be resorted to, falling within the scope of the invention.

What is claimed as new is as follows:

1. An expandable bellows assembly for use with a camper structure and being selectively movable between an expanded condition and a collapsed condition, said assembly comprising inner and outer sheets of flexible material, said sheets being fastened together by a plurality of seams which form a first plurality of pockets between said inner and outer sheets, a first group of elongated, planar slats, one extending into each of said first group of pockets to provide relatively rigid sections for said bellows assembly between each of said seams, each of said seams being substantially horizontal such that the adjacent pockets and slats therein overlie each other to form a first expandable wall, a second group of elongated pockets defined by said seams in said sheets of flexible material, a second group of elongated, planar slats in said second group of pockets each extending in a direction substantially parallel to a corresponding slat of said first group of pockets, third and fourth groups of elongated pockets defined by said seams in said sheets, and third and fourth groups of elongated, planar slats in said third and fourth groups of pockets, respectively, each slat in said third group of pockets extending in a direction substantially parallel to a corresponding slat in said fourth group of pockets, the opposite ends of each of said pockets of said third and fourth groups of pockets abutting opposite ends of each of said pockets of said first and second groups of pockets, each of said third and fourth pockets and slats extending in directions substantially perpendicular to said first and second groups of pockets and slats, said slats in said first and second 40 jacent each triangular groups of pockets each being generally rectangular in shape with a pair of parallel end edges, said slats of said third and fourth groups of pockets each being generally trapezoidal in shape with a pair of parallel edges and a pair of non-parallel end edges, one of said parallel edges being longer than the other such that the end portions of adjacent slats of said third and fourth groups are in substantially horizontal, side-by-side relation-with each other and the end portions of adjacent slats of said first and second groups are in substantially horizontal side-by-side relation with each other when said assembly is in said collapsed condition.

2. The assembly set forth in claim 1 wherein the parallel edges of all of said trapezoidal slats are substantially parallel to each other, the adjacent parallel edges of the adjacent slats being of equal length.

3. The assembly set forth in claim 2 wherein each of the ends of the longer of said parallel edges of said trapezoidal slats meets with a corresponding end of a nonparallel edge to form an acute comer, each of said corners being adjacent to a corresponding corner of an end edge of said rectangular shaped slats to provide a generally triangular flexing section between the ends of each trapezoidal and rectangular shaped slat.

4. The assembly set forth in claim 3 wherein each of said triangular flexing sections is substantially parallel to an adjoining adjacent rectangular slat when said bellows assembly is in the collapsed position.

5. The assembly set forth in claim 4 wherein each of said triangular flexing sections is substantially perpendicular to an adjacent rectangular slat when said bellows assembly is in the fully expanded position.

6. The assembly set forth in claim 5 herein said inner sheet of flexible material has a triangular opening within each of said triangular flexing sections to provide easier flexing of the bellows assembly.

7. The assembly set forth in claim 6 wherein an elongated narrow piece of said inner sheet extends between the adjacent flexing triangular sections in the area of said seam to provide additional strength to the seam adflexing section. 

1. An expandable bellows assembly for use with a camper structure and being selectively movable between an expanded condition and a collapsed condition, said assembly comprising inner and outer sheets of flexible material, said sheets being fastened together by a plurality of seams which form a first plurality of pockets between said inner and outer sheets, a first group of elongated, planar slats, one extending into each of said first grouP of pockets to provide relatively rigid sections for said bellows assembly between each of said seams, each of said seams being substantially horizontal such that the adjacent pockets and slats therein overlie each other to form a first expandable wall, a second group of elongated pockets defined by said seams in said sheets of flexible material, a second group of elongated, planar slats in said second group of pockets each extending in a direction substantially parallel to a corresponding slat of said first group of pockets, third and fourth groups of elongated pockets defined by said seams in said sheets, and third and fourth groups of elongated, planar slats in said third and fourth groups of pockets, respectively, each slat in said third group of pockets extending in a direction substantially parallel to a corresponding slat in said fourth group of pockets, the opposite ends of each of said pockets of said third and fourth groups of pockets abutting opposite ends of each of said pockets of said first and second groups of pockets, each of said third and fourth pockets and slats extending in directions substantially perpendicular to said first and second groups of pockets and slats, said slats in said first and second groups of pockets each being generally rectangular in shape with a pair of parallel end edges, said slats of said third and fourth groups of pockets each being generally trapezoidal in shape with a pair of parallel edges and a pair of non-parallel end edges, one of said parallel edges being longer than the other such that the end portions of adjacent slats of said third and fourth groups are in substantially horizontal, side-by-side relation with each other and the end portions of adjacent slats of said first and second groups are in substantially horizontal side-byside relation with each other when said assembly is in said collapsed condition.
 2. The assembly set forth in claim 1 wherein the parallel edges of all of said trapezoidal slats are substantially parallel to each other, the adjacent parallel edges of the adjacent slats being of equal length.
 3. The assembly set forth in claim 2 wherein each of the ends of the longer of said parallel edges of said trapezoidal slats meets with a corresponding end of a non-parallel edge to form an acute corner, each of said corners being adjacent to a corresponding corner of an end edge of said rectangular shaped slats to provide a generally triangular flexing section between the ends of each trapezoidal and rectangular shaped slat.
 4. The assembly set forth in claim 3 wherein each of said triangular flexing sections is substantially parallel to an adjoining adjacent rectangular slat when said bellows assembly is in the collapsed position.
 5. The assembly set forth in claim 4 wherein each of said triangular flexing sections is substantially perpendicular to an adjacent rectangular slat when said bellows assembly is in the fully expanded position.
 6. The assembly set forth in claim 5 wherein said inner sheet of flexible material has a triangular opening within each of said triangular flexing sections to provide easier flexing of the bellows assembly.
 7. The assembly set forth in claim 6 wherein an elongated narrow piece of said inner sheet extends between the adjacent flexing triangular sections in the area of said seam to provide additional strength to the seam adjacent each triangular flexing section. 